Febri Budi Darsono, Akhmad Nurdin, Fajar Paundra, Alvreando Kaleb Thomas, Tasih Mulyono, Muhammad Irfan Nuryanta, Hendrix Noviyanto Firmansyah, Aldias Bahatmaka, Deni Fajar Fitriyana, Kriswanto, Rahmat Doni Widodo, Nurul Muhayat
The Aluminum 1100 series is widely used because of its high corrosion resistance and ductility. Joining aluminum by conventional welding is challenging due to its poor weldability. Friction Stir Welding (FSW) is a solid-state joining process in which heat is generated by the tool's rotation pin and shoulder rubbing against the material to be welded, stirring it. The FSW process can reduce welding issues when joining aluminum materials. The quality of the joint formed by friction stir welding depends on the welding parameters, as evidenced by numerous prior investigations. However, previous research has been limited to mechanical strength of welded joints, using destructive testing methods. This allows researchers to examine the quality of welded joints using nondestructive testing. Researchers focus on investigating the quality of friction stir welding joints on an AA 1100 thin plate. The tool used has three flat sides with a tool pin and shoulder diameter ratio of 1:3. The parameters used were variations in the tool's lateral tilt angle, with values of 0°, 0.5°, and 1°. The travel speed was 45 mm/minute with a tool rotation of 1860 rpm. The clamp/fixture was made of S45C, a heat-treated material; the backing plate was mild steel. The AA 1100 material, thicker than 2 mm, undergoes welding. The quality of FSW joints was inspected using nondestructive testing methods, including visual, radiographic, and eddy-current testing. In contrast, mechanical strength was assessed by tensile testing to validate the nondestructive test. The results indicated that tilt angle 0° had no defects, tilt angle 0.5° had tunneling or voids, and tilt angle 1° had defects in the form of a lack of material. When the tilt angle was changed to 0°, the tensile strength was 85.53 MPa, and the joint efficiency was 78. When the tilt angle was set to 0.5° and 1°, the tensile strength dropped to 61.84 MPa and 71.91 MPa, respectively. © 2026 The Author(s). Published by Universiti Malaysia Pahang Al-Sultan Abdullah Press. This is an open access article under the CC BY-NC 4.0 International license
Department of Mechanical Engineering, Universitas Negeri Semarang, Sekaran, Gunung Pati, Semarang, 50299, Indonesia; Department of Manufacturing Design Engineering, Universitas Tidar, Magelang Utara, Jawa Tengah, 56116, Indonesia; Department of Mechanical Engineering, Faculty of Industrial Technology, Institut Teknologi Sumatera, Lampung, 35365, Indonesia; Department of Quality Control, PT Ramai Jaya Abadi, Murung Pudak, Tabalong, Kalimantan Selatan, 71571, Indonesia; Politeknik Teknologi Nuklir Indonesia, Depok, Sleman Yogyakarta, Caturtunggal, 55281, Indonesia; Department of Mechanical Engineering, Universitas Sebelas Maret, Surakarta, 57126, Indonesia
